Pyrometer control for hot drape formers

ABSTRACT

An apparatus for hot drape forming a part includes a plurality of pyrometers, a bladder covering a formable material, and a pyrometer control medium positioned between the plurality of pyrometers and the formable material. The plurality of pyrometers are configured to measure a temperature of the pyrometer control medium.

FIELD

This disclosure relates generally to hot drape forming processes, andmore particularly to temperature control for hot drape formingprocesses.

BACKGROUND

Hot drape forming (HDF) allows composite materials of parts to be formedinto curved or contoured shapes. In the context of composite materials,HDF includes heating a composite material and urging the heatedcomposite material against a curved or contoured forming tool.Non-uniform heating of the composite material during HDF, often causedby inaccurate temperatures readings of the composite material, may leadto undesired deformation or inconsistencies in the part. With currentHDF techniques, accurately monitoring the temperatures of compositematerials so as to promote uniform heating of the composite materialscan be difficult.

SUMMARY

The subject matter of the present application has been developed inresponse to the present state of the art, and in particular, in responseto the problems and disadvantages associated with conventional hot drapeforming processes that have not yet been fully solved by currentlyavailable techniques. Accordingly, the subject matter of the presentapplication has been developed to provide embodiments of a system, anapparatus, and a method that overcome at least some of theabove-discussed shortcomings of prior art techniques. For example,according to one implementation, a hot drape forming process isdisclosed, which facilitates consistent temperature readings throughouta part.

Disclosed herein is an apparatus for hot drape forming a part. Theapparatus includes a plurality of pyrometers, a bladder covering aformable material, and a pyrometer control medium positioned between theplurality of pyrometers and the formable material. The plurality ofpyrometers are configured to measure a temperature of the pyrometercontrol medium. The preceding subject matter of this paragraphcharacterizes example 1 of the present disclosure.

The pyrometer control medium is between the bladder and the plurality ofpyrometers. The preceding subject matter of this paragraph characterizesexample 2 of the present disclosure, wherein example 2 also includes thesubject matter according to example 1, above.

The pyrometer control medium is a surface treatment applied onto thebladder. The preceding subject matter of this paragraph characterizesexample 3 of the present disclosure, wherein example 3 also includes thesubject matter according to example 2, above.

The pyrometer control medium rests on the bladder. The preceding subjectmatter of this paragraph characterizes example 4 of the presentdisclosure, wherein example 4 also includes the subject matter accordingto example 2, above.

The pyrometer control medium is integrated into the bladder. Thepreceding subject matter of this paragraph characterizes example 5 ofthe present disclosure, wherein example 5 also includes the subjectmatter according to example 2, above.

The pyrometer control medium has a surface roughness of greater thantwenty microns. The preceding subject matter of this paragraphcharacterizes example 6 of the present disclosure, wherein example 6also includes the subject matter according to any one of examples 1-5,above.

The pyrometer control medium has a gloss of less than four gloss units.The preceding subject matter of this paragraph characterizes example 7of the present disclosure, wherein example 7 also includes the subjectmatter according to any one of examples 1-6, above.

The pyrometer control medium includes a polyester mat. The precedingsubject matter of this paragraph characterizes example 8 of the presentdisclosure, wherein example 8 also includes the subject matter accordingto example 7, above.

The pyrometer control medium includes a black matted material. Thepreceding subject matter of this paragraph characterizes example 9 ofthe present disclosure, wherein example 9 also includes the subjectmatter according to any one of examples 1-8, above.

The pyrometer control medium includes a plurality of spaced apartpatches. Each one of the plurality of spaced apart patches is placeddirectly below a respective one of the plurality of pyrometers. Thepreceding subject matter of this paragraph characterizes example 10 ofthe present disclosure, wherein example 10 also includes the subjectmatter according to any one of examples 1-9, above.

The thickness of the pyrometer control medium is less than one-fifth ofan inch. The preceding subject matter of this paragraph characterizesexample 11 of the present disclosure, wherein example 11 also includesthe subject matter according to any one of examples 1-10, above.

The pyrometer control medium includes a felt material. The precedingsubject matter of this paragraph characterizes example 12 of the presentdisclosure, wherein example 12 also includes the subject matteraccording to any one of examples 1-11, above.

The pyrometer control medium includes a latex material. The precedingsubject matter of this paragraph characterizes example 13 of the presentdisclosure, wherein example 13 also includes the subject matteraccording to any one of examples 1-12, above.

The pyrometer control medium has a uniform thickness. The precedingsubject matter of this paragraph characterizes example 14 of the presentdisclosure, wherein example 14 also includes the subject matteraccording to any one of examples 1-13, above.

Also disclosed herein is a hot drape forming system. The system includesan apparatus including a plurality of pyrometers, a bladder covering aformable material, and a pyrometer control medium positioned between theplurality of pyrometers and the formable material. The plurality ofpyrometers are configured to measure a temperature of the pyrometercontrol medium. The system further includes a plurality of heat sourcesand a controller, configured to control the plurality of heat sourcesbased on temperature readings of the plurality of pyrometers. Thepreceding subject matter of this paragraph characterizes example 15 ofthe present disclosure.

The plurality of heat sources are divided into zones. Each one of theplurality of pyrometers corresponds to one of the zones and thecontroller is configured to turn each zone on and off based on acorresponding one of the plurality of pyrometers. The preceding subjectmatter of this paragraph characterizes example 16 of the presentdisclosure, wherein example 16 also includes the subject matteraccording to example 15, above.

The controller is configured to predict a temperature of the formablematerial based on the temperature of the pyrometer control medium. Thepreceding subject matter of this paragraph characterizes example 17 ofthe present disclosure, wherein example 17 also includes the subjectmatter according to any one of examples 15 or 16, above.

Additionally disclosed herein is a method of controlling a hot drapeformer. The method includes positioning a pyrometer control mediumbetween a plurality of pyrometers and a bladder covering a formablematerial. The method also includes measuring a temperature of thepyrometer control medium with the plurality of pyrometers. The methodfurther includes predicting a temperature of the formable material basedon the temperature of the pyrometer control medium. The precedingsubject matter of this paragraph characterizes example 18 of the presentdisclosure.

Positioning the pyrometer control medium between the plurality ofpyrometers and the bladder covering the formable material includespositioning a matted material between the bladder and the plurality ofpyrometers. The preceding subject matter of this paragraph characterizesexample 19 of the present disclosure, wherein example 19 also includesthe subject matter according to example 18, above.

Positioning the pyrometer control medium between the plurality ofpyrometers and a bladder covering the formable material includesapplying the pyrometer control medium onto the bladder as a surfacetreatment. The preceding subject matter of this paragraph characterizesexample 20 of the present disclosure, wherein example 20 also includesthe subject matter according to any one of examples 19 or 20, above.

The described features, structures, advantages, and/or characteristicsof the subject matter of the present disclosure may be combined in anysuitable manner in one or more embodiments and/or implementations. Inthe following description, numerous specific details are provided toimpart a thorough understanding of embodiments of the subject matter ofthe present disclosure. One skilled in the relevant art will recognizethat the subject matter of the present disclosure may be practicedwithout one or more of the specific features, details, components,materials, and/or methods of a particular embodiment or implementation.In other instances, additional features and advantages may be recognizedin certain embodiments and/or implementations that may not be present inall embodiments or implementations. Further, in some instances,well-known structures, materials, or operations are not shown ordescribed in detail to avoid obscuring aspects of the subject matter ofthe present disclosure. The features and advantages of the subjectmatter of the present disclosure will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of the subject matter as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the subject matter may be more readilyunderstood, a more particular description of the subject matter brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the subject matter and arenot therefore to be considered to be limiting of its scope, the subjectmatter will be described and explained with additional specificity anddetail through the use of the drawings, in which:

FIG. 1 is a side elevation view of an apparatus for hot drape forming apart, according to one or more embodiments of the present disclosure;

FIG. 2 is a side elevation view of a detail of a bladder and a pyrometercontrol medium of the apparatus of FIG. 1 , according to one or moreembodiments of the present disclosure;

FIG. 3 is a top plan view of heat sources and pyrometers of an apparatusfor hot drape forming a part, according to one or more embodiments ofthe present disclosure;

FIG. 4 is a side elevation view of an apparatus for hot drape forming apart, according to one or more embodiments of the present disclosure;

FIG. 5 is a block diagram of a hot drape forming system, according toone or more embodiments of the present disclosure; and

FIG. 6 is a schematic flow diagram of a method of hot drape forming apart, according to one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present disclosure.Appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment. Similarly, the use of theterm “implementation” means an implementation having a particularfeature, structure, or characteristic described in connection with oneor more embodiments of the present disclosure, however, absent anexpress correlation to indicate otherwise, an implementation may beassociated with one or more embodiments.

Referring to FIG. 1 , one embodiment of an apparatus 100 for hot drapeforming (HDF) a part is shown. The apparatus 100 is used implement anHDF process. As will be described in more detail below, the apparatus100 includes a temperature control system, which promotes accurate andmore uniform temperature control throughout the apparatus 100.

The apparatus 100 includes a frame 102 and a plurality of heat sources104. The frame 102 is a structure or casing that houses, supports, orunderpins the various components of the apparatus 100 and the elementsutilized with the apparatus 100. The frame 102 has upper and lowerportions which move relative to each other and may form an enclosableinterior space. The plurality of heat sources 104 are attached to theframe 102. The plurality of heat sources 104 may be any of various typesof heat sources including, but not limited to, heat lamps, heat coils,heat elements, etc. The plurality of heat sources 104 may also beattached at various locations within or external to the apparatus 100,including to the frame 102, above the frame 102, or below the frame 102.In some embodiments, the plurality of heat sources 104 are co-movablycoupled to the frame 102. In some embodiments, the heat sources 104 arenot attached to the frame 102 but are positioned to heat the interiorspace.

The apparatus 100 is configured to form a formable material 112 into apart. The formable material 112 is a sheet of material made of a singlematerial or a plurality of materials that are formable when heatedincluding composite materials. The formable material may be, withoutlimitation, a laminate or a laminate charge including a carbon fiberreinforced plastic (CFRP) or polymer-matrix composites. The plurality ofheat sources 104 are configured to heat the formable material 112, whichis positioned within the apparatus 100 on top of a male tool 110, whichcan be mandrel-like.

In an HDF process, after the heat sources 104 heat the formable material112 to a temperature sufficient to promote deformation of the formablematerial 112 over the male tool 110, applied force(s) conformsoverhanging edges of the formable material 112 onto the male tool 110.In some embodiments, the applied force(s) is caused by a pressuredifferential to the formable material 112 to form it over the male tool110. Referring to FIG. 1 , a vacuum is created under a bladder 106(sometimes referred to as a membrane or diaphragm) in cavity 125, whichcauses a pressure differential within the cavity 125. The pressuredifferential causes the bladder 106 to apply a force to the formablematerial 112 which presses the overhanging edges of the formablematerial 112 onto the male tool 110. The bladder 106 is a flexible,stretchable material such as, without limitation, a silicone.

Also positioned within the apparatus 100 are stand-off blocks 114, whichhelp to reduce the weight and force the bladder 106 applies onto theformable material 112 prior to applying the pressure differential. Thestand-off blocks 114 are positioned around a periphery of the male tool110 to support a portion of the weight of the bladder 106 to preventforcing the formable material 112 down onto the male tool 110 prior toreaching an appropriate temperature.

Temperature variations along the formable material 112 may lead tonon-conformance of formed parts. In contrast, temperature uniformityacross the formable material 112 helps to increase optimal properties ofa formed part and reduces the need to scrap non-conforming parts. Theapparatus 100 utilizes feedback mechanisms, including a temperaturecontrol system, to regulate the heating of and temperature uniformityacross the formable material 112. The feedback mechanisms operablycontrol the heat sources 104 (e.g., activate and deactivate the heatsources 104, modulate the heat generated by the heat sources 104, etc.)to promote temperature uniformity across the formable material 112.

Embodiments described herein utilize pyrometers 108 to provide feedback.A pyrometer, sometimes referred to as infrared thermometers, is a typeof remote-sensing thermometer used to measure the temperature of asurface. Pyrometers determine the temperature of a surface from adistance using a process known as pyrometry or radiometry. Generally,pyrometry or radiometry includes detecting the spectrum of thermalradiation, sometimes called blackbody radiation, the surface emits. Thepyrometers 108 are pointed in a direction towards the formable material112. In the illustrated embodiment, the pyrometers 108 are attached toand positioned in fixed locations along the frame 102. In someembodiments, the pyrometers 108 may be repositionable along the frame102 to adjust the location of the pyrometers 108 relative to theformable material 112. For example, the pyrometers 108 may be slidablein slots formed in the frame 102 and releasably tightenable in desiredlocations within the slots to temporarily prevent relative movement ofthe pyrometers 108 and the frame 102. In some implementations, thelocation of the pyrometers 108 is adjustable based on the size and/orshape of the part to be formed.

The pyrometers 108 are positioned to sense the temperature of theformable material 112. However, as shown in FIG. 1 , some solidfeatures, such as the bladder 106, may be interposed between thepyrometers 108 and the formable material 112. Accordingly, thepyrometers 108 do not directly sense the temperature of the formablematerial 112, but rather indirectly sense the temperature of theformable material 112 based on directly sensing the temperature of thesolid features between the pyrometers 108 and the formable material 112.In other words, the temperature of the formable material 112 ispredicted based on temperature readings of an intermediate surface.Accurate readings of the intermediate surface promote accuratepredictions or indirect readings of the temperature of the formablematerial 112. To promote accurate predictions of the temperature of theformable material 112, the apparatus 100 includes a pyrometer controlmedium 116 positioned below the plurality of pyrometers 108 and abovethe bladder 106 and formable material 112. The pyrometer control medium116 is configured to promote more accurate temperature readings by thepyrometers 108, which leads to more accurate predictions of thetemperature of the formable material 112.

As presented above, the pyrometers 108 are configured to measure orremote sense a temperature of the pyrometer control medium 116. Thepyrometer control medium 116 may be a covering or sheet positioned overand resting on the bladder 106, may be separate from the bladder 106 orattached to the bladder 106, may be a surface treatment applied onto thebladder 106, or may be part of the bladder 106.

In those embodiments where the pyrometer control medium 116 is acovering or sheet positioned over and resting on the bladder 106, thepyrometer control medium 116, can be a thin sheet of material of uniformthickness or substantially uniform thickness (e.g., a thickness within atolerance of the surface roughness of the material). The sheet ofmaterial is of a size that enables the pyrometer control medium 116 tospan across and cover the bladder 106. In some implementations, thepyrometer control medium 116 is not a uniform thickness.

In some embodiments, the pyrometer control medium 116 may be separatefrom the bladder 106. The pyrometer control medium 116 is not connectedor attached to the bladder 106 in any manner. The contact between thepyrometer control medium 116 and the bladder 106 allows for heattransfer to occur and for accurate temperature readings while notinhibiting or affecting the movement of the bladder 106 once thepressure differential is applied as the pyrometer control medium maymove relative to the bladder 106.

In some embodiments, the pyrometer control medium 116 is attached to thebladder 106. In such embodiments, the pyrometer control medium 116 maybe more secure and also ensures placement of the pyrometer controlmedium 116 is consistent or repeatable from part to part. For example,the pyrometer control medium 116 may be adhered to the bladder 106 by anadhesive material, or stitched or sewn to the bladder 106, or otherwiseattached. The pyrometer control medium 116 may be co-movably attached.

In some embodiments, the pyrometer control medium 116 is not separatefrom the bladder 106 but is applied as a surface treatment to thebladder 106. For example, the pyrometer control medium 116 may bepainted directly on the bladder 106. The painted on pyrometer controlmedium 116 allows for more accurate readings of the pyrometers withoutthe need of a separate sheet of material. In other implementations, thepyrometer control medium 116 may be other surface treatment applicationsthat are applied to the bladder 106.

In some embodiments, the pyrometer control medium 116 may be part of thebladder 106. Instead of applying the pyrometer control medium 116 to thebladder 106 as a surface treatment, the formation or manufacturing ofthe bladder 106 may include the pyrometer control medium 116. Forexample, the pyrometer control medium 116 may be integrated into thebladder 106 or co-formed with the bladder 106. In some implementations,the bladder 106 may be made of a material with the same color, texture,and/or surface characteristics as those described herein and function asthe pyrometer control medium 116.

Referring to FIG. 2 , a detailed view of the pyrometer control medium116 and the bladder 106 is shown. The pyrometer control medium 116includes a surface 117 which is configured to be exposed to theplurality of pyrometers 108. The surface may be rough. In someembodiments, the surface roughness is greater than twenty microns. Insome embodiments, the surface roughness is greater than three hundredand fifty microns. In some embodiments, the surface roughness is greaterthan four hundred microns. The surface roughness may be dependent uponthe type of material utilized for the pyrometer control medium 116. Insome embodiments, the pyrometer control medium 116 is a matted material.

To enhance accurate temperature sensing, the pyrometer control medium116 is made of a material with a color that is relatively dark. In someembodiments, the pyrometer control medium 116 is black. In someembodiments, the pyrometer control medium 116 is gray. The pyrometercontrol medium 116 may be other dark colors or shades including green,brown, blue, or purple. The darkness in color and/or brightness may alsobe dependent upon the type of material utilized for the pyrometercontrol medium 116. In some embodiments, the pyrometer control medium116 includes a lightness of less than 30 L* as measured in a CIELABcolor space or lab color space.

The pyrometer control medium 116 may be made of any of various materialsthat are sufficiently dark and provide an acceptable texture. Thepyrometer control medium 116 may be rubber, felt, latex, polyester,silicon, aluminum foil, and/or other like materials.

To enhance accurate temperature sensing, the pyrometer control medium116 may be below a particular level of gloss. In some embodiments, thepyrometer control medium 116 includes a gloss of less than four glossunits. In some embodiments, the pyrometer control medium includes agloss of less than ten gloss units. Gloss may be measured by use of agloss meter which measures the specular reflection gloss of a surface.

To enhance accurate temperature sensing and also allow for heating ofthe formable material 112, the pyrometer control medium 116 may beconfigured to be a thickness which allows for efficient heat transfer.In some embodiments, the pyrometer control medium 116 may be a uniformthickness across the bladder 106. In some embodiments, the pyrometercontrol medium 116 includes a thickness of not greater than one-fifth ofan inch. In some embodiments, the pyrometer control medium 116 includesa thickness of not greater than one inch. In some embodiments, thepyrometer control medium 116 includes a thickness of not greater thanone-twentieth of an inch. The thickness of the pyrometer control medium116 may also be dependent upon the type of material utilized for thepyrometer control medium 116. Materials that more efficiently transferheat may generally be thicker than materials that are less efficient atheat transfer.

The pyrometer control medium 116 may contact the bladder 106. Contactbetween the pyrometer control medium 116 and the bladder 106 may allowfor more even heat transfer distribution between the pyrometer controlmedium 116 and the bladder 106 and for more accurate relationshipbetween the temperature of the pyrometer control medium 116 and thebladder 106. The same principle may be applied between the bladder 106and the formable material 112. Contact between the bladder 106 and theformable material 112 may allow for more even heat transfer distributionbetween the bladder 106 and the formable material 112 and more accuraterelationship between the temperature of the bladder 106 and the formablematerial 112.

The positioning of the pyrometers 108 may also lead to differenttemperature readings. As the center of the formable material 112 restson the male tool 110, the center of the formable material 112 may heatmore slowly than the exterior edges of the formable material which hangout over male tool 110. A single reading at the center of the formablematerial 112 may result in a lower temperature reading and relying ononly the reading at the center of the formable material 112 may resultin overshoot of temperature on the exterior edges of the formablematerial 112, which hang out over male tool 110.

As shown in FIG. 3 , to combat the heating variances between variousparts of the formable material, the heat source 104 may be divided intoheating zones 120 a-120 e. As depicted, a grid of heat sources 104 in apredetermined pattern are attached to the frame 102. The operation ofthe heat sources 104 may be controlled individually and/or by heatingzone. In the illustrated embodiment, the heat sources 104 are dividedinto 5 separate heating zones 120 a-120 e. Each heating zone may beindependently controlled and operated relative to the other heatingzones. For example, heat sources 104 in heating zones 120 b, 120 c, and120 d may continue to produce heat while the heat sources 104 in heatingzones 120 a and 120 e are turned off.

The independent heating zones 120 a-120 e may be controlled (e.g.,activated (turned on), deactivated (turned off), and adjusted) based onthe independent readings of the pyrometers 108 a-108 e. The individualpyrometers 108 a-108 e may each provide independent readings to allowfor control of when to turn on and off the heat sources 104 of theircorresponding heating zones 120 a-120 e. For example, the operation ofthe heat sources 104 of heating zone 120 a may be dependent on thereadings gathered by pyrometer 108 a, while the heat sources 104 ofheating zone 120 b may be dependent on the readings gathered bypyrometer 108 b, and so on.

In the illustrated embodiment, the heating zones 120 a-120 e each has asingle corresponding pyrometer 108 a-108 e. In some embodiments, theheating zones 120 a-120 e may include more than one pyrometer 108. Insuch cases, the operation of the heat sources 104 in a particularheating zone 120 a-120 e may be dependent on an average or blending ofthe multiple readings from pyrometers 108 in the particular heating zone120 a-120 e.

In some embodiments, the heating zones 120 a-120 e may be adjustabledepending on the size and shape of the formable material 112 to beformed and/or the size and shape of the male tool 110. In addition, thepyrometers 108 a-108 e may be activated/deactivated oracknowledged/ignored based on the heating zones 120 a-120 e selected.For example, in some embodiment, an apparatus 100 may include aplurality of pyrometers 108 which are in fixed locations within theapparatus 100. Depending on the size and shape of the formable material112 to be formed and/or the size and shape of the male tool 110, certainpyrometers 108 may be turned off or the readings may be ignored duringthe operation of the apparatus.

The pyrometer control medium 116 may cover the entirety of the bladder106. In some embodiments, the pyrometer control medium 116 does notcover the entirety of the bladder 106. Referring to FIG. 4 , thepyrometer control medium 116 is a plurality of patches 116 a, 116 b, and116 c. In the illustrated embodiment, the patches 116 a, 116 b, and 116c are placed directly below the pyrometers 108. In some embodiments, thepyrometers 108 are configured to point at the patches 116 a, 116 b, and116 c. This allows the pyrometers 108 to remote sense the temperature atthe patches 116 a, 116 b, and 116 c instead of the bladder 106 which mayrender inaccurate temperature readings.

Referring now to FIG. 5 , a block diagram of a hot drape forming system200 is shown. The system 200 allows for control and operation of thevarious embodiments of the apparatus 100 described herein. The systemmay include various components, not illustrated, to allow for control ofthe apparatus described herein, such as, but not limited to, processors,memory, computer hardware and software, and modules. The system 200includes various components including the components described inconjunction with the embodiments of the apparatus 100 described herein.

The illustrated block diagram includes the heat sources 104, thepyrometers 108, the bladder 106, the formable material 112, and thepyrometer control medium 116. The hot drape forming system 200 furtherincludes a controller 205 which allows for controlling the apparatus 100and the various components of the apparatus 100 and system 200.

The controller 205 may be configured to control operation of the heatsources 104, the pyrometers 108, and the heating zones 120 a-120 e aswas described above in conjunction with FIGS. 1-4 . With the pyrometers108 fixed in position in the apparatus 100 and the ability to controlthe heat sources 104, the pyrometers 108, and the heating zones 120a-120 e through the controller 205, set up labor and time for forming ofparts may be significantly reduced. Individual heat sensors need not beplaced with each new part or differently sized part as is done withconventional thermocouples utilized in hot drape formers. The pyrometers108 are fixed and can be activated/deactivated or acknowledged/ignoredbased on inputs to the controller 205.

Now referring to FIG. 6 , one embodiment of a method 300 of controllinga hot drape former is shown. The method 300 includes pointing aplurality of pyrometers at a formable material at 302 and positioning apyrometer control medium between the plurality of pyrometers and abladder covering the formable material at 304. At 306, the method 300includes measuring a temperature of the pyrometer control medium withthe plurality of pyrometers. The method then ends.

In some embodiments, positioning the pyrometer control medium betweenthe plurality of pyrometers and the bladder covering the formablematerial includes positioning a matted material above the bladder. Insome embodiments, positioning the pyrometer control medium between theplurality of pyrometers and the bladder covering the formable materialincludes applying the pyrometer control medium onto the bladder as asurface treatment.

Although described in a depicted order, the method of controlling a hotdrape former may proceed in any of a number of ordered combinations. Asexample, the pyrometer may be positioned prior to or after pointing theplurality of pyrometers at the formable material.

In the above description, certain terms may be used such as “up,”“down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,”“over,” “under” and the like. These terms are used, where applicable, toprovide some clarity of description when dealing with relativerelationships. But, these terms are not intended to imply absoluterelationships, positions, and/or orientations. For example, with respectto an object, an “upper” surface can become a “lower” surface simply byturning the object over. Nevertheless, it is still the same object.Further, the terms “including,” “comprising,” “having,” and variationsthereof mean “including but not limited to” unless expressly specifiedotherwise. An enumerated listing of items does not imply that any or allof the items are mutually exclusive and/or mutually inclusive, unlessexpressly specified otherwise. The terms “a,” “an,” and “the” also referto “one or more” unless expressly specified otherwise. Further, the term“plurality” can be defined as “at least two.”

Additionally, instances in this specification where one element is“coupled” to another element can include direct and indirect coupling.Direct coupling can be defined as one element coupled to and in somecontact with another element. Indirect coupling can be defined ascoupling between two elements not in direct contact with each other, buthaving one or more additional elements between the coupled elements.Further, as used herein, securing one element to another element caninclude direct securing and indirect securing. Additionally, as usedherein, “adjacent” does not necessarily denote contact. For example, oneelement can be adjacent another element without being in contact withthat element.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of the items in the list may be needed. Theitem may be a particular object, thing, or category. In other words, “atleast one of” means any combination of items or number of items may beused from the list, but not all of the items in the list may berequired. For example, “at least one of item A, item B, and item C” maymean item A; item A and item B; item B; item A, item B, and item C; oritem B and item C. In some cases, “at least one of item A, item B, anditem C” may mean, for example, without limitation, two of item A, one ofitem B, and ten of item C; four of item B and seven of item C; or someother suitable combination.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

As used herein, a system, apparatus, structure, article, element,component, or hardware “configured to” perform a specified function isindeed capable of performing the specified function without anyalteration, rather than merely having potential to perform the specifiedfunction after further modification. In other words, the system,apparatus, structure, article, element, component, or hardware“configured to” perform a specified function is specifically selected,created, implemented, utilized, programmed, and/or designed for thepurpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware which enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, structure, article,element, component, or hardware described as being “configured to”perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

The schematic flow chart diagram included herein is generally set forthas logical flow chart diagrams. As such, the depicted order and labeledsteps are indicative of one embodiment of the presented method. Othersteps and methods may be conceived that are equivalent in function,logic, or effect to one or more steps, or portions thereof, of theillustrated method. Additionally, the format and symbols employed areprovided to explain the logical steps of the method and are understoodnot to limit the scope of the method. Although various arrow types andline types may be employed in the flow chart diagrams, they areunderstood not to limit the scope of the corresponding method. Indeed,some arrows or other connectors may be used to indicate only the logicalflow of the method. For instance, an arrow may indicate a waiting ormonitoring period of unspecified duration between enumerated steps ofthe depicted method. Additionally, the order in which a particularmethod occurs may or may not strictly adhere to the order of thecorresponding steps shown.

The present subject matter may be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive. All changes which come within themeaning and range of equivalency of the claims are to be embraced withintheir scope.

What is claimed is:
 1. A method of controlling a hot drape former, themethod comprising: positioning a pyrometer control medium between aplurality of pyrometers and a bladder covering a formable material;measuring a temperature of the pyrometer control medium with theplurality of pyrometers; and predicting a temperature of the formablematerial based on the temperature of the pyrometer control medium,wherein positioning the pyrometer control medium between the pluralityof pyrometers and the bladder comprises attaching the pyrometer controlmedium to the bladder.
 2. The method according to claim 1, whereinattaching the pyrometer control medium to the bladder comprisesattaching a matted material to the bladder.
 3. The method according toclaim 1, wherein attaching the pyrometer control medium to the bladdercomprises applying the pyrometer control medium onto the bladder as asurface treatment.
 4. The method according to claim 1, furthercomprising: heating the pyrometer control medium and the formablematerial with a plurality of heat sources that are divided into zones,wherein at least one of the plurality of pyrometers corresponds to eachone of the zones; and turning one or more heat sources of the pluralityof heat sources associated with each zone on or off based on temperaturefeedback from the at least one pyrometer of the plurality of pyrometerscorresponding with the zone.
 5. The method according to claim 4, whereinturning the one or more heat sources of the plurality of heat sourcesassociated with each zone on or off is based on temperature feedbackfrom more than one pyrometer of the plurality of pyrometerscorresponding with the zone.
 6. The method according to claim 4, whereinheating the pyrometer control medium and the formable material with aplurality of heat sources comprises individually controlling the one ormore heat sources associated with one of the zones relative to the oneor more heat sources associated with another of the zones.
 7. The methodaccording to claim 4, further comprising adjusting a quantity of theheat sources forming at least one of the zones based on a size or shapeof the formable material.
 8. The method according to claim 1, whereinattaching the pyrometer control medium to the bladder comprisesattaching a plurality of spaced apart patches to the bladder.
 9. Themethod according to claim 8, wherein attaching the plurality of spacedapart patches to the bladder comprises placing each one of the pluralityof spaced part patches directly below a respective one of the pluralityof pyrometers.
 10. The method according to claim 1, wherein attachingthe pyrometer control medium to the bladder comprises co-movablyattaching the pyrometer control medium to the bladder.
 11. The methodaccording to claim 1, wherein attaching the pyrometer control medium tothe bladder comprises adhering the pyrometer control medium to thebladder.
 12. The method according to claim 1, wherein attaching thepyrometer control medium to the bladder comprises stitching thepyrometer control medium to the bladder.
 13. The method according toclaim 1, wherein attaching the pyrometer control medium to the bladdercomprises positioning the pyrometer control medium in direct contactwith the bladder.
 14. The method according to claim 13, wherein directlycontacting the bladder with the pyrometer control medium comprisesdirectly contacting the bladder with the pyrometer control medium suchthat the bladder is movable relative to the pyrometer control medium.15. A method of controlling a hot drape former, the method comprising:positioning a pyrometer control medium between a plurality of pyrometersand a bladder covering a formable material; resting the pyrometercontrol medium on the bladder; measuring a temperature of the pyrometercontrol medium with the plurality of pyrometers; and predicting atemperature of the formable material based on the temperature of thepyrometer control medium.
 16. The method according to claim 15, furthercomprising: positioning at least one stand-off block adjacent theformable material; and resting a portion of the bladder on the at leastone stand-off block.
 17. A method of controlling a hot drape former, themethod comprising: positioning a bladder between a plurality ofpyrometers and a formable material; surface treating the bladder to forma pyrometer control medium between the plurality of pyrometers and theformable material; measuring a temperature of the pyrometer controlmedium with the plurality of pyrometers; and predicting a temperature ofthe formable material based on the temperature of the pyrometer controlmedium.
 18. The method according to claim 17, wherein surface treatingthe bladder comprises integrating the pyrometer control medium into thebladder.
 19. The method according to claim 17, wherein surface treatingthe bladder comprises painting the pyrometer control medium directly onthe bladder.
 20. The method according to claim 17, wherein surfacetreating the bladder comprises applying the pyrometer control mediumdirectly on the bladder.